Luggage &amp; method of manufacture

ABSTRACT

Luggage includes a body formed by walls. At least one of the walls comprises at least in part a sheet of architectural laminate with an exterior decorative surface providing at least in part the exterior surface of a portion of the luggage.

INCORPORATION BY REFERENCE

The inventor incorporates herein by reference any and all U.S. patents,U.S. patent applications, and other documents, hard copy or electronic,cited or referred to in this application.

Definitions

The words “comprising,” “having,” “containing,” and “including,” andother forms thereof, are intended to be equivalent in meaning and beopen ended in that an item or items following any one of these words isnot meant to be an exhaustive listing of such item or items, or meant tobe limited to only the listed item or items.

The word luggage shall mean any container adapted to hold solid objectsthat may be lifted and carried by a single adult human being, and isintend to include, for example, attaché cases, brief cases, hand bags,suit cases, tote bags, etc.

The word “rectangular” includes square.

BACKGROUND OF INVENTION

Style and design are important factors that consumers consider whenpurchasing luggage. Strength and ruggedness is also important. Ideally,a line of luggage having unique style and design characteristics thatalso imparts strength and ruggedness to the luggage is highly desirable.

SUMMARY OF INVENTION

In accordance with this invention architectural laminates are employedas an exterior finish for luggage. Such architectural laminates impartboth style and strength to the luggage and give a designer a vast numberof decorative surfaces to choose from in designing fashionable luggage.

Architectural laminates, which are commonly used in the constructionindustry, comprise a substantially rigid sheet material that provides adecorative veneer. Such a laminate may simply be thin a sheet of a metalhaving an exterior surface shaped, finished, stamped, or otherwisetreated to provide a decorative or aesthetic look to the exteriorsurface. Typically, such a laminate has a thickness that is no greaterthan 0.10 inch, for example, having a thickness substantially from 0.025to 0.10 inch. Any form of art or graphic or pictorial treatment may bedisplayed as a decorative surface. Such laminates may also comprisemulti-layers of sheet material or a paper impregnated with a resin suchas, for example, described in U.S. Pat. No. 4,473,613. A commoncharacteristic of architectural laminates is that the laminate sheet maybe bent or otherwise formed into a desired shape and it will retain thisshape after being so formed. For example, a flat, planar metal laminatesheet may be bent into a curved sheet, or a flat, planar resinimpregnated laminate sheet may be heated so that it may be reshapedwhile at an elevated temperature, and upon cooling, remain in thereshaped configuration. Other architectural laminates are disclosed inU.S. Pat. Nos. 5,418,034 and 6,472,083.

This invention has one or more features as discussed subsequentlyherein. After reading the following section entitled “DETAILEDDESCRIPTION OF SOME EMBODIMENTS OF THIS INVENTION,” one will understandhow the features of this invention provide its benefits. The benefits ofthis invention include, but are not limited to: enabling a designer touse architectural laminates in new ways to improve both the appearanceand ruggedness of luggage.

Without limiting the scope of this invention as expressed by the claimsthat follow, some, but not necessarily all, of its features are:

One, the luggage of this invention has a body formed by walls, at leastone of which comprises at least in part a sheet of architecturallaminate with an exterior decorative surface providing at least in partan exterior surface of a portion of the luggage.

Two, the architectural laminate may be fastened directly to a wall ofthe luggage, and a layer of backing material may be underneath thearchitectural laminate. For example, the backing material may comprisean open or closed cell foam plastic sheet, a polymer sheet of, forexample, styrene or ABS, a woven/non-woven textile material, Neoprenerubber, etc.

Three, the walls of the luggage body form an interior adapted to holdobjects and is accessible through an opening in the body. The openingmay or may not be covered; it may or may not be closed by a zipper orother type of opening and closing device.

Four, the body may have a first wall segment comprising a pliable sheetmaterial, and a second wall segment comprising an architecturallaminate. The sheet of architectural laminate initially may be planarand at least a portion thereof may be formed into a predeterminednon-planar shape that maintains this predetermined wall shape afterbeing so formed or reshaped. This formed sheet of architectural laminatemay be included in the body of the luggage.

Five, an edge portion of the pliable sheet material of the wall segmentand an edge portion of the sheet of architectural laminate may beattached together. For example, the edge portions may be attachedtogether by sewing or by an adhesive. The edge portions may have apiping therebetween.

These features are not listed in any rank order nor is this listintended to be exhaustive.

This invention also includes a method of manufacturing luggage.According to this method a luggage body is formed including at least oneportion thereof comprising a pliable sheet and another portion thereofcomprising a sheet of architectural laminate with an exterior decorativesurface providing at least in part an exterior surface of said luggage.An edge portion of the wall comprising the pliable sheet material may beattached to an edge portion of the sheet of architectural laminate. Thesheet of architectural laminate initially may be planar and at least aportion thereof may be reshaped into a predetermined non-planar shapethat maintains this predetermined wall shape after being so reshaped andincluded in the luggage body. The edge portions may have a pipingpositioned therebetween.

The advantages of using architectural laminates have not been fullyappreciated by the luggage industry. Luggage is manufactured frommultiple parts and different processes that vary depending on the designof the finished product. These factors must be carefully considered indesigning luggage, and often the finished product is the result ofchosen compromises in structure, utility, and aesthetic appeal due toexpenses associated with these factors. Using architectural laminates inmanufacturing luggage avoids the many compromises previously necessaryto offer luggage at a competitive price. This is achieved withoutsacrificing (1) structural integrity and strength imparted to luggagebecause of inherent weight to strength ratio of architectural laminates,(2) enhanced protection of objects contained within the luggage, and (3)a refinement of aesthetics unobtainable with other materials because ofthe multiple, decorative surface finishes available. Architecturallaminates also provide cost savings by reducing the number of luggageparts and by reducing the labor costs in assembly due to fewer thenumber of parts and ease of fabrication.

Traditional methods of manufacturing may be used in the method of thisinvention, for example:

Sewing & stitching. Architectural laminates may be fastened this way byforming laminate panel or panels in a particular style of luggage andsewing and stitching a ‘pocket’ or ‘frame’ around a substrate carryingthe to hold it in place. The laminate panel or panels can be fabricatedwith holes therein trough which a thread passes during sewing.

Chemical adhesives and/or tapes. Architectural laminates may be bondedwith an adhesive or tape to a surface structure of luggage or edges ofadjoining laminate pieces may be fastened together in this manner.

Mechanical fastening. Architectural laminates may be mechanicallyfastened by nut and bolt hardware, screws, nails, rivets, magnetism,trims and reveals, clips, and other mechanical fastening devices to asurface structure of luggage or edges of adjoining laminate pieces maybe fastened together in this manner.

Stamping. Architectural laminates because they come in sheet form may beeasily cut into different silhouettes by stamping or other means. Thislends itself to facilitating low cost manufacture of luggage.

DESCRIPTION OF THE DRAWING

Some embodiments of this invention, illustrating all its features, willnow be discussed in detail. These embodiments depict the novel andnon-obvious luggage and method of this invention as shown in theaccompanying drawing, which is for illustrative purposes only. Thisdrawing includes the following figures (Figs.), with like numeralsindicating like parts:

FIG. 1 is a perspective view of one embodiment of the luggage of thisinvention.

FIG. 2 is an exploded perspective view of the luggage shown in FIG. 1.

FIG. 2A is a cross-sectional view taken along line 2A-2A of FIG. 2.

FIG. 3 is a cross-sectional view of a wall of a conventional luggagepiece.

FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. 1.

FIG. 5 is a cross-sectional view of a wall of a piece of conventionalluggage.

FIG. 6 is a cross-sectional view of adjoining walls of luggageconstructed in accordance with one embodiment of this invention.

FIG. 7 is a perspective view of another embodiment of the luggage ofthis invention.

FIG. 8 is a cross-sectional view of adjoining walls of luggageconstructed in accordance with another embodiment of this invention.

FIG. 9 is a cross-sectional view of adjoining walls of luggageconstructed in accordance with yet another embodiment of this invention.

FIG. 10 is a cross-sectional view of adjoining walls of luggageconstructed in accordance with still another embodiment of thisinvention.

FIG. 11 is a cross-sectional view of adjoining walls of luggageconstructed in accordance with one more embodiment of this invention.

FIG. 12 is a cross-sectional view of adjoining walls of luggageconstructed in accordance with another embodiment of this invention.

FIG. 13 is a cross-sectional view taken along line 13-13 of FIG. 7.

DETAILED DESCRIPTION OF SOME EMBODIMENTS OF THIS INVENTION General

The luggage of this invention may have many different embodiments, andtwo embodiments are depicted in FIGS. 1 and 7, and respectivelyidentified by the numerals 10 and 10 a. Common to all the embodiments ofthis invention is the use of a sheet of architectural laminate with anexterior decorative surface that provides at least in part the exteriorsurface of a portion of the luggage. Suitable architectural laminatesmay be purchased under the trademark Formica, or from such companies asFormwwod Industries, Chemetal, Nevamar, Brookside Vaneer, Wilsonart,Pionite, Ridgewood, ABET Laminati, Braewood, ARPA USA, or Laminart. Thearchitectural laminate in addition to enhancing the appearance of theluggage provides improved strength and ruggedness. Moreover, becausearchitectural laminate sheets come in so many forms, and have so manydifferent varieties of decorative surfaces, a luggage designer has awide selection to choose from, allowing the designer to be more creativein designing and styling luggage. The architectural laminate sheet formsa portion of some, but not all, of the walls of the luggage. Otherwalls, or portions thereof, are formed from pliable sheet material suchas, for example, leather, plastics, textile material such as fabrics,that have durability and are flexible, being capable of bending orfolding, and are generally soft so they may be penetrated by a sharpobject such as a knife. Compared to this pliable sheet material,architectural laminate sheet material is very rigid, inflexible, hard,and impenetrable.

The architectural laminate may be fastened directly to a wall of anexisting piece of luggage, for example, by gluing it to the exterior ofthe luggage wall. Or, a wall of a piece of luggage may be made from onesheet of architectural laminate or multiple layers of sheet materialwith the architectural laminate being the outer sheet with itsdecorative surface exposed to view. A layer of backing material may ormay not be positioned underneath the architectural laminate. Suitablebacking sheet material may comprise, for example, an open or closed cellfoam plastic sheet, a polymer sheet of, for example, styrene or ABS, awoven/non-woven textile material, Neoprene rubber, etc.

FIGS. 1 through 4

As illustrated in FIGS. 1 and 2, the luggage 10 is a brief casecomprising a body 12 providing an interior 14 accessible through anopening 16 in the body. A pair of straps 18 with buckles 20 enable amanually moveable cover wall section 22 to be held in place in a closedposition as shown in solid lines in FIG. 1 to cover the opening 16. Byunbuckling the straps 18 and moving the cover wall section 22 to an openposition shown in dotted lines in FIG. 1, a user may place objects inthe interior 14 of the luggage 10.

One desirable feature of this invention is that the luggage body 12 maybe constructed from one or more walls that are substantially rigid andinflexible because they include a sheet of architectural laminate. Forexample, the architectural laminate sheets 24 a, 24 b, and 24 c areglued by an adhesive 26 to a foam backing sheet 28 that underlies eachof the laminate sheets as depicted in FIG. 2A. This assembly of multiplelayers of sheets is then attached, for example, typically by sewing orgluing the assembly to an exterior surface 22 a (FIG. 2) of the coverwall section 22. The decorative surfaces S1 of these sheets 24 a, 24 b,and 24 c are exposed to view. These surfaces may be the same ordifferent, displaying any form of art or graphic or pictorial treatment.

Another desirable feature is that the luggage 10 may be constructed sosome of the walls forming the body 12, or portions thereof, are made ofa pliable sheet material and other walls, or portions thereof, include asheet of architectural laminate. As illustrated best in FIGS. 3 and 4, atop wall 28 includes an internal support member 30 having a pliablesheet material 31 wrapped around the support member. The support member30 may comprises cardboard, corrugated paper, an open or closed cellfoam plastic sheet, a solid polymer sheet such as styrene or ABS,textile material, Neoprene rubber, leather, and adds some rigidity tothe top wall. A handle 32 is mounted to the exterior of the top wall.The pliable sheet material 31 has an underside portion 31 a abutting aportion of the cover wall section 22, which is a pliable sheet material.This is standard practice and provides the type of body constructionshown in FIG. 3. In contrast, in this invention the architecturallaminate sheet 24 c is glued and/or sewn, or otherwise attachedtogether, to the cover wall section 22 as illustrated in FIG. 4.Straight, or looped, conventional stitching 25 is used in the luggage 10to attach an edge portion ED1 of the pliable sheet material of the topwall 28 and an edge portion ED2 of the substantially rigid architecturallaminate sheet 24 c.

Many types of architectural laminates that are substantially planarsheets may be reconfigured. Thus, an initially planar architecturallaminate sheet, or at least a portion thereof, is reshaped into apredetermined non-planar shape that maintains this predetermined,non-planar wall shape after being reshaped. This reconfigured laminatesheet may be included in the body of the luggage. For example, the endsof the laminate sheets 24 a, 24 b, and 24 c are reconfigured into acurved segment S2 that overlaps the cover wall section 22 where thissection joins the top wall 28 as depicted in FIG. 4. When a thin metallaminate sheet is employed, simply bending the appropriate end forms thecurved segment S2. When a multilayered, resin impregnated laminate sheetis employed, the sheet is heated to an elevated temperature, and whilehot, formed into the desired shaped such as the curved segment S2. Thenthis reshaped sheet is allowed to cool. When cooled, the desired shapedis maintained; in this case the curved segment S2.

FIGS. 5 and 6

FIG. 5 depicts a conventional luggage piece having adjoining walls A andB attached by stitches 17. A stiffening member 11 is lodged betweenpliable sheets 13 and 15, forming the wall A to enhance the rigidity ofthis one wall A. As shown in FIG. 6, such a stiffening member 11 and thesheet 13 are eliminated when a planar architectural laminate sheet, forexample, the sheet C is used. This sheet C may use a foam backing sheet28 beneath the architectural laminate sheet C, which is bonded theretoby an adhesive 26.

FIGS. 7 and 13

The luggage 10 a illustrated in FIG. 7 is a suitcase where substantiallyflat wall segments are covered with planar architectural laminate sheets40 and 42. In the luggage 10 a adjacent parallel walls 44 and 46 are,respectively, covered by or formed from the laminate sheets 40 and 42.As best depicted in FIG. 13, the wall 46 and a top wall 47 are connectedalong a junction J and these walls are substantially at a right anglewith respect to each other. The top wall 47, which has a handle 49attached thereto, comprises a pliable sheet, for example, a woven nylonfabric or leather or a vinyl plastic. The wall 44 is rectangular and itincludes the rectangular, substantially planar sheet 40 with itsdecorative surface S3 exposed to view. The wall 46 provides a frame forthe wall 44, and it includes the planar sheet 42 with its decorativesurface S4 exposed to view. In this embodiment, the planar architecturallaminate sheets 40 and 42 retain their planar configuration and are notreformed to alter their shape. The architectural laminate sheet 42 maybe stamped from a sheet with the unused cutout central portion salvagedand used in another luggage piece.

As best illustrated in FIG. 13, a conventional piping 50 is sewn bystitches 52 along the rectangular edges ED3 and ED4 respectively of thelaminate sheets 40 and 42. This piping 50 is positioned along thejunction between the laminate sheets 40 or 42, as the case may be, andan adjacent pliable sheet, for example the top wall 47. A foam backingsheet 28 is beneath the laminate sheet 42, which is attached by anadhesive 26 to the foam backing sheet.

FIGS. 8 through 12

FIGS. 8 through 12 illustrate different ways to attach a pliable wallsegment to a wall segment employing an architectural laminate sheet,whether or not reshaped. In FIG. 8, an edge portion ED5 of anarchitectural laminate sheet 60 is inserted into a pocket 62 formed inthe end of a wall segment 64 comprising the pliable sheet material. Onlythe architectural laminate sheet 60 is used to form an adjoining wallsegment, thereby eliminating any cost associated with the foam backingsheet 28. Some rigidity is imparted to the pliable wall segment 64 by aninternal support member 30, which lies approximately in the same planeas the architectural laminate sheet 60. Stitches 52 and adhesive 26 holdthe pliable wall segment 64 to the architectural laminate sheet 60. Thewall construction shown in FIG. 9 is almost identical to thatillustrated in FIG. 8, except a foam backing sheet 28 is bonded to thearchitectural laminate sheet 60 with the adhesive 26 and a pliable sheet64 a projects outward from the wall segment 64 to extend beneath thelaminate sheet 60, providing a space 61 between the pliable sheet 64 aand the foam backing sheet 28. The pliable sheet 64 a may be a fabriclining for the interior of the luggage, for example, silk.

FIGS. 10 11, and 12 show slightly different connection systems thandiscussed above for attaching a pliable wall segment to a wall segmentemploying an architectural laminate sheet. FIG. 10 depicts a pliablewall segment 70 that includes overlying pliable sheets 70 a and 70 bwith an internal support member 30 between these sheets. The sheet 70 bextends under a laminate sheet 74 and forms a part of a wall segment 72.The portion P of the sheet 70 b extending under the laminate sheet 74has the laminate sheet 74 bonded to it as discussed above using anadhesive 26 and stitches 52. FIG. 11 shows essentially the sameconnection system as FIG. 10, except the internal support member 30 iseliminated.

The connection system illustrated in FIG. 12 is like that depicted inFIG. 13, except the wall segments E and F. The wall segment E (thesegment including the architectural laminate sheet 24) and the wallsegment F (the pliable wall segment) instead of being at a right anglewith respect to each other are approximately in the same plane.

Scope of the Invention

The above presents a description of the best mode contemplated ofcarrying out the present invention, and of the manner and process ofmaking and using it, in such full, clear, concise, and exact terms as toenable any person skilled in the art to which it pertains to make anduse this invention. This invention is, however, susceptible tomodifications and alternate constructions from that discussed abovewhich are fully equivalent. Consequently, it is not the intention tolimit this invention to the particular embodiments disclosed. On thecontrary, the intention is to cover all modifications and alternateconstructions coming within the spirit and scope of the invention asgenerally expressed by the following claims, which particularly pointout and distinctly claim the subject matter of the invention:

1. Luggage comprising a body providing an interior accessible through anopening in the body, said interior being adapted to hold objects, saidbody having a first wall segment comprising a pliable sheet material,and a second wall segment comprising a substantially rigid sheetmaterial having an exterior decorative surface.
 2. The luggage of claim1 where the substantially rigid sheet material is a sheet ofarchitectural laminate.
 3. The luggage of claim 2 where the sheet ofarchitectural laminate initially is planar and at least a portionthereof is reshaped into a predetermined non-planar shape that maintainssaid predetermined wall shape after being reshaped and included in thebody of the luggage.
 4. The luggage of claim 1 where an edge portion ofthe pliable sheet material of the wall segment and an edge portion ofthe substantially rigid sheet material of the second wall segment areattached together.
 5. The luggage of claim 4 where the edge portions areattached together by sewing.
 6. The luggage of claim 4 where the edgeportions are attached together by an adhesive.
 7. The luggage of claim 4where the edge portions have a piping therebetween.
 8. Luggagecomprising a plurality of walls joined together to form a body providingan interior accessible through an opening in the body, said interiorbeing adapted to hold objects, a first wall comprising a pliable sheetmaterial, and a second wall comprising a substantially rigid sheet ofarchitectural laminate having an exterior decorative surface thatprovides at least a portion of an exterior surface of said second wall,and where an edge portion of the pliable sheet material of the firstwall and an edge portion of the sheet of architectural laminate of thesecond wall are attached together.
 9. The luggage of claim 8 where thesheet of architectural laminate initially is planar and at least aportion thereof is reshaped into a predetermined non-planar shape thatmaintains said predetermined wall shape after being reshaped andincluded in the second wall.
 10. The luggage of claim 8 where the edgeportions are attached together by sewing.
 11. The luggage of claim 8where the edge portions are attached together by an adhesive.
 12. Theluggage of claim 8 where the edge portions have a piping therebetween.13. Luggage comprising a body formed by walls, at least one of saidwalls comprising at least in part a sheet of architectural laminate withan exterior decorative surface providing at least in part an exteriorsurface of a portion of the luggage.
 14. The luggage of claim 13 wherethe architectural laminate is fastened directly to a wall of theluggage.
 15. The luggage of claim 13 including a layer of backingmaterial underneath the architectural laminate.
 16. The luggage of claim15 where the backing material comprises cardboard, corrugated paper, anopen or closed cell foam plastic sheet, a solid polymer sheet, textilematerial, Neoprene rubber, or leather.
 17. A method of manufacturingluggage comprising (a) forming a plurality of walls into a body of theluggage including an interior adapted to hold objects and accessiblethrough an opening in the body, one of said walls comprising a pliablesheet material, and another of said walls comprising a substantiallyrigid sheet of architectural laminate having an exterior decorativesurface that provides at least a portion of an exterior surface of theluggage, and (b) attaching said walls together.
 19. The method of claim18 where an edge portion of the wall comprising the pliable sheetmaterial is attached to an edge portion of the sheet of architecturallaminate.
 20. The method of claim 18 where the sheet of architecturallaminate initially is planar and at least a portion thereof is reshapedinto a predetermined non-planar shape that maintains said predeterminedwall shape after being reshaped and included in the second wall.
 21. Themethod of claim 18 where the edge portions have a piping therebetween.22. A method of manufacturing luggage comprising forming a luggage bodyincluding at least one portion thereof comprising a pliable sheet andanother portion thereof comprising a sheet of architectural laminatewith an exterior decorative surface providing at least in part anexterior surface of said luggage.
 24. The method of claim 22 where anedge portion of the wall comprising the pliable sheet material isattached to an edge portion of the sheet of architectural laminate. 25.The method of claim 22 where the sheet of architectural laminateinitially is planar and at least a portion thereof is reshaped into apredetermined non-planar shape that maintains said predetermined wallshape after being reshaped and included in the luggage body.